CN110073017B - Aluminum alloy and manufacturing method thereof - Google Patents
Aluminum alloy and manufacturing method thereof Download PDFInfo
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- CN110073017B CN110073017B CN201780077507.9A CN201780077507A CN110073017B CN 110073017 B CN110073017 B CN 110073017B CN 201780077507 A CN201780077507 A CN 201780077507A CN 110073017 B CN110073017 B CN 110073017B
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
- C22C21/04—Modified aluminium-silicon alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
- C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
Abstract
High strength aluminum alloys and methods of making and processing such alloys are disclosed. More specifically, aluminum alloys exhibiting improved mechanical strength are disclosed. The processing method comprises homogenization, hot rolling, solutionizing and multi-step quenching. In some cases, the processing step may further comprise annealing and/or cold rolling.
Description
Cross Reference to Related Applications
The present application claims U.S. provisional application No. 62/435,437 entitled "aluminum alloy and method of making same" filed 2016, 12, 16; and U.S. provisional application No. 62/529,516 entitled "aluminum alloy and method of making same" filed on 7/2017, the entire contents of which are incorporated herein by reference in their entirety.
Technical Field
The present disclosure relates to aluminum alloys and related methods.
Background
Recyclable aluminum alloys having high strength are desirable for improving product performance in a number of applications, including transportation (including but not limited to, for example, trucks, trailers, trains, and ships) applications, electronics applications, and automotive applications. For example, high strength aluminum alloys in trucks or trailers are lighter than conventional steel alloys, providing a significant amount of emissions reduction to meet new, more stringent government emissions regulations. Such alloys should exhibit high strength. However, identifying the processing conditions and alloy compositions that will provide such alloys has proven to be a challenge.
Disclosure of Invention
The encompassed embodiments of the invention are defined by the following claims, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some concepts that are further described below in the detailed description section. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all of the drawings, and each claim.
The invention discloses a method for producing an aluminum alloy, which comprises the following steps: casting a cast aluminum product; homogenizing the cast aluminum product; hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge; optionally cold rolling the aluminum alloy body of the first gauge into an aluminum alloy plate, sheet (shate), or slab of a second gauge; solutionizing the aluminum alloy sheet, plate or plate; quenching the aluminum alloy plate, the thin plate or the plate; rolling the aluminum alloy plate, sheet or plate into a coil; pre-aging the coil; and optionally aging the coil.
In some non-limiting examples, the quenching step may include a multi-step quenching process including a first quenching to a first temperature and a second quenching to a second temperature. In some examples, the aluminum alloy may include about 0.45-1.5 wt.% Si, about 0.1-0.5 wt.% Fe, up to about 1.5 wt.% Cu, about 0.02-0.5 wt.% Mn, about 0.45-1.5 wt.% Mg, up to about 0.5 wt.% Cr, up to about 0.01 wt.% Ni, up to about 0.1 wt.% Zn, up to about 0.1 wt.% Ti, up to about 0.1 wt.% V, and up to about 0.15 wt.% impurities, with the remainder being Al. In some examples, the method may comprise a third quench to a third temperature.
In some examples, a method of producing an aluminum alloy includes casting a cast aluminum product; homogenizing the cast aluminum product; hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge; cold rolling the aluminum alloy body of the first gauge into an aluminum alloy plate, sheet or plate of a second gauge; solutionizing the aluminum alloy sheet, plate or plate; quenching the aluminum alloy plate, sheet or plate including a first quenching to a first temperature, a second quenching to a second temperature, and a third quenching to a third temperature; and rolling the aluminum alloy plate, sheet or plate into a coil.
In some non-limiting examples, the quenching step described above can be performed with water, air, or a combination thereof.
In some non-limiting examples, the quenching may include quenching to a first temperature in the range of about 100 ℃ to about 300 ℃ and then may include quenching to a second temperature in the range of about 20 ℃ to about 200 ℃ during the multi-step quenching step described herein. In some examples, the second temperature may be room temperature (e.g., about 20 ℃ to about 25 ℃). In some cases, the multi-step quench may involve several process steps. In some cases, the multi-step quench includes 2 steps, 3 steps, 4 steps, 5 steps, 6 steps, 7 steps, 8 steps, 9 steps, 10 steps, or more than 10 steps. In some further cases, the multi-step quenching step includes process substeps. The multi-step quench may comprise any combination of process steps and process sub-steps.
In some examples, a method of producing an aluminum alloy includes casting a cast aluminum product; homogenizing the cast aluminum product; hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge; cold rolling the aluminum alloy body of the first gauge into an aluminum alloy plate, sheet or plate of a second gauge; solutionizing the aluminum alloy sheet, plate or plate; quenching the aluminum alloy plate, sheet or plate including a first quenching to a first temperature, a second quenching to a second temperature, and a third quenching to a third temperature; flash-heating the aluminum alloy sheet, plate or plate and rolling the aluminum alloy sheet, plate or plate into a coil. In some examples, the quenching step may comprise quenching to room temperature, and the flash heating may comprise heating to about 200 ℃ for about 10 seconds to 60 seconds. After the flash-heating step, the aluminum alloy may be cooled to room temperature and then subjected to additional processing steps, such as pre-aging or pre-straining.
In some non-limiting examples, the flash heating described above includes heating the coil to a temperature and maintaining the coil at the temperature for a period of time. The flash temperature of the coil may comprise a temperature in the range of about 150 ℃ to about 200 ℃. The flash time of the sustaining coil may comprise a time period in a range of about 5 seconds to about 60 seconds.
In some non-limiting examples, the pre-aging described above may further include heat treatment. In some aspects, the heat treatment further increases the strength of the aluminum alloy sheet, plate or plate. The heat treatment comprises heating the aluminum alloy sheet, plate or plate to a temperature of about 150 c to about 225 c for about 10 minutes to about 60 minutes. In some aspects, the pre-straining further increases the strength of the aluminum alloy sheet, plate or plate. The pre-straining includes straining the aluminum alloy sheet, plate or plate to about 0.5% to about 5%. The heat treatment simulates baking finish. The pre-strain may mimic the forming of an aluminum alloy part.
In some non-limiting examples, aluminum alloy sheet, plate, or plate having improved yield strength can be provided using the above-described process comprising multi-step quenching and pre-aging and/or pre-straining. The aluminum alloy, sheet or plate is provided in an exemplary T8x temper.
In some non-limiting examples, the aluminum alloy sheet, plate, or slab described above has a yield strength of at least 270MPa when in the T8x temper.
In some non-limiting examples, the methods described herein including exemplary quenching and pre-aging steps can provide an improved speed for an aluminum alloy processing line, such as at least 20% faster than a comparative aluminum alloy processing method.
In some non-limiting examples, the aluminum alloy compositions incorporating the methods described above can be used to produce aluminum alloy products. The aluminum alloy product may be a transportation body part or an electronic device case.
Other aspects, objects, and advantages of the invention will become apparent from a consideration of the following detailed description and the accompanying drawings.
Drawings
The specification refers to the following drawings, in which the use of the same reference numbers in different drawings is intended to illustrate the same or similar components.
FIG. 1 is a schematic illustration of a process flow of the methods described herein.
FIG. 2 is a graph illustrating the thermal history of exemplary alloys described herein as a function of time.
Fig. 3 is a bar graph illustrating yield strength of samples taken from exemplary alloys in the T8x temper described herein.
Fig. 4 is a bar graph illustrating the bake hardening response (i.e., increase in yield strength) of samples taken from the exemplary alloys described herein.
FIG. 5 is a graph illustrating a bake hardening response according to the temperature of exemplary alloys described herein after exiting the first quenching step described herein.
Fig. 6 is a bar graph illustrating yield strength of samples taken from alloys described herein subjected to various fabrication methods described herein.
Fig. 7 is a bar graph illustrating the bake hardening response (i.e., increase in yield strength) of samples taken from alloys described herein that have undergone the various methods of preparation described herein.
Fig. 8 is a bar graph showing the yield strength of samples taken from the alloys described herein before and after the paint bake procedure described herein.
Fig. 9 is a bar graph illustrating yield strength of samples taken from aluminum alloys described herein subjected to various fabrication methods described herein.
Fig. 10 is a bar graph illustrating the bake hardening response (i.e., increase in yield strength) of samples taken from alloys described herein subjected to various methods of preparation described herein.
Fig. 11 is a graphical diagram illustrating yield strength of samples taken from aluminum alloys described herein subjected to various methods of fabrication described herein.
Fig. 12 is a graph illustrating the bake hardening response (i.e., increase in yield strength) of samples taken from alloys described herein subjected to various methods of preparation described herein.
FIG. 13 is a graph illustrating bake hardening response of samples taken from alloys described herein subjected to various methods of preparation described herein.
Fig. 14 is a graph illustrating the resulting strength after a paint bake procedure for exemplary aluminum alloys produced at different line speeds according to the methods described herein.
FIG. 15 is a graph illustrating measured tensile strength for various alloys made according to different methods and techniques.
Fig. 16 is a graph showing the yield strength of samples taken from an exemplary alloy in the T8x temper and subjected to various paint bake procedures described herein.
Fig. 17 is a graph illustrating bake hardening response (i.e., increase in yield strength) for samples taken from exemplary alloys and subjected to various paint bake procedures described herein.
Fig. 18 is a bar graph illustrating yield strength of samples taken from exemplary alloys in the T8x temper described herein.
Fig. 19 is a bar graph illustrating the bake hardening response (i.e., increase in yield strength) of samples taken from the exemplary alloys described herein.
Detailed Description
Certain aspects and features of the present disclosure relate to quenching techniques that improve paint bake response in certain aluminum alloys.
As used herein, the terms "invention," "the invention," "this invention," and "the invention" are intended to refer broadly to all subject matter of the present patent application and the claims that follow. Statements containing these terms should be understood as not limiting the subject matter described herein or as not limiting the meaning or scope of the patent claims below.
In this specification, reference is made to alloys identified by AA values and other relevant designations such as "series". For an understanding of The digital marking system most commonly used for naming and marking Aluminum and its Alloys, see "International Alloy nomenclature and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration records of Aluminum Association Alloy names and Chemical Composition Limits for Aluminum Alloys in cast and Ingot Form" (Registration records of Aluminum Association Alloy nomenclature and Chemical Composition Limits for Aluminum Alloys in The Form of Castings and ingots), "both published by The Aluminum Association (The Aluminum Association).
As used herein, the meaning of "a" and "the" includes both singular and plural references unless the context clearly dictates otherwise.
As used herein, "room temperature" can mean a temperature of about 15 ℃ to about 30 ℃, e.g., about 15 ℃, about 16 ℃, about 17 ℃, about 18 ℃, about 19 ℃, about 20 ℃, about 21 ℃, about 22 ℃, about 23 ℃, about 24 ℃, about 25 ℃, about 26 ℃, about 27 ℃, about 28 ℃, about 29 ℃, or about 30 ℃.
All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to include any and all subranges between minimum value 1 and maximum value 10 (and including minimum value 1 and maximum value 10); that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.
Throughout this application, elements are expressed in weight percent (wt.%). The sum of the impurities in the alloy must not exceed 0.15 wt.%. The remainder of each alloy is aluminum.
The term T4 temper or the like refers to an aluminum alloy that has been solutionized and then naturally aged to a substantially steady state. The T4 temper applies to alloys that are not cold rolled after solutionizing, or the effect of cold rolling in cold rolling or straightening may not be recognized within the mechanical property limits.
The term T6 temper refers to an aluminum alloy that has been solution heat treated and artificially aged.
The term T8 temper refers to an aluminum alloy that has been solution heat treated, then cold worked or rolled, and then artificially aged.
The term F temper refers to the aluminum alloy as manufactured.
As used herein, terms such as "cast metal product," "cast aluminum product," and the like are interchangeable and refer to a product produced by direct chill (including direct chill) or semi-continuous casting, continuous casting (including, for example, by using a twin belt caster, twin roll caster, block caster, or any other caster), electromagnetic casting, hot top casting, or any other casting method.
Composition of aluminum alloy
Described below is an aluminum alloy. In certain aspects, the alloy exhibits high strength. The properties of the alloy are achieved by the method of processing the alloy to produce the plate, sheet, plate or other product. In some examples, the alloys may have the following elemental compositions as provided in table 1.
TABLE 1 alloy compositions
| Alloy (I) | Si | Fe | Cu | Mn | Mg | Cr | Ni | Zn | Ti | V |
| C1 | 0.5-1.3 | 0.1-0.3 | 0.0-0.4 | 0.02-0.2 | 0.5-1.3 | 0.0-0.25 | 0.0-0.01 | 0.0-0.1 | 0.0-0.1 | 0.0-0.1 |
| A1 | 0.5-1.0 | 0.1-0.3 | 0.5-1.0 | 0.0-0.2 | 0.8-1.0 | 0.0-0.3 | 0.0-0.05 | 0.0-0.1 | 0.0-0.05 | 0.0-0.05 |
| B1 | 0.8-1.0 | 0.0-0.3 | 0.7-0.9 | 0.0-0.2 | 0.8-1.0 | 0.0-0.3 | 0.0-0.05 | 0.0-0.05 | 0.0-0.05 | 0.0-0.05 |
| G1 | 1.0-1.5 | 0.0-0.5 | 1.0-1.5 | 0.0-0.5 | 1.0-1.5 | 0.1-0.5 | 0.0-0.05 | 0.0-0.1 | 0.0-0.05 | 0.0-0.05 |
All values are weight percent (wt.%) of the whole.
In certain examples, the alloy includes silicon (Si) in an amount of about 0.45% to about 1.5% (e.g., 0.5% to 1.1%, 0.55% to 1.25%, 0.6% to 1.0%, 1.0% to 1.3%, or 1.03% to 1.24%) by total weight of the alloy. For example, the alloy may comprise 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.6%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.7%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.8%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.9%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.99%, 1.86%, 1.87%, 1.88%, 1.9%, 1.06%, 1.1.1.1.1.1.1.1.1%, 1.9%, 1.1.1.9%, 1.91%, 1.2%, 1.1.1.1.1.1%, 1.9%, 1.1.9%, 1%, 1.93%, 1.1.1.1.1.1%, 1.1%, 1.9%, 1.8%, 1%, 1.1.1.1.1%, 1%, 1.1.1.1%, 1%, 1.1%, 1%, 1.06, 1.28%, 1.29%, 1.3%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.4%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49% or 1.5% Si. All expressed in wt.%.
In certain examples, the alloy includes iron (Fe) in an amount of about 0.1% to about 0.5% (e.g., 0.15% to 0.25%, 0.14% to 0.26%, 0.13% to 0.27%, or 0.12% to 0.28%) by total weight of the alloy. For example, the alloy may comprise 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, or 0.5% Fe. All expressed in wt.%.
In certain examples, the alloy includes copper (Cu) in an amount of about 0.0% to about 1.5% (e.g., 0.1% to 0.2%, 0.3% to 0.4%, 0.05% to 0.25%, 0.04% to 0.34%, or 0.15% to 0.35%) by total weight of the alloy. For example, the alloy may comprise 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, or 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, 0.54%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.53%, 0.54%, 0.75%, 0.66%, 0.75%, 0.67%, 0.75%, 0.66%, 0.67%, 0.75%, 0.66%, 0.67%, 0.75%, 0.60%, 0.75%, 0., 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.9%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.0%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.1%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.2%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.3%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.42%, 1.45%, 1.46%, 1.45%, 1.19%, 1.2%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.38%, 1.42%, 1.48%, 1.42%, 1.45% or 1.45%. In some cases, Cu is not present in the alloy (i.e., 0%). All expressed in wt.%.
Cu may be included in the aluminum alloy to increase strength and hardness after solutionizing and optional aging. The higher amount of Cu contained in the aluminum alloy can significantly reduce the formability after solutionizing and optionally aging. In some non-limiting examples, aluminum alloys with small amounts of Cu may provide increased strength and good formability when produced by the example methods described herein.
In certain examples, the alloy may include manganese (Mn) in an amount of about 0.02% to about 0.5% (e.g., 0.02% to 0.14%, 0.025% to 0.175%, about 0.03%, 0.11% to 0.19%, 0.08% to 0.12%, 0.12% to 0.18%, 0.09% to 0.18%, and 0.02% to 0.06%) by total weight of the alloy. For example, the alloy may comprise 0.02%, 0.021%, 0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%, 0.031%, 0.032%, 0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.041%, 0.042%, 0.043%, 0.044%, 0.045%, 0.046%, 0.047%, 0.048%, 0.049%, 0.05%, 0.051%, 0.052%, 0.053%, 0.054%, 0.061055%, 0.056%, 0.057%, 0.098%, 0.06%, 0.050.060%, 0.060.060.060%, 0.080.080%, 0.080.099%, 0.080.080.099%, 0.070.079%, 0.079%, 0.099%, 0.05%, 0.052%, 0.060.0.0.050.050.060%, 0.050.050%, 0.050%, 0.050.060%, 0.050.050.050%, 0.080%, 0%, 0.080.080%, 0.080%, 0%, 0.080.080.080.080%, 0%, 0.080%, 0%, 0.098%, 0.080.080.080.080, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, or 0.5% Mn. All expressed in wt.%.
In certain examples, the alloy includes magnesium (Mg) in an amount of about 0.45% to about 1.5% (e.g., about 0.6% to about 1.3%, about 0.65% to 1.2%, 0.8% to 1.2%, or 0.9% to 1.1%) by total weight of the alloy. For example, the alloy may comprise 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.6%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.7%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.8%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.9%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.99%, 1.86%, 1.87%, 1.88%, 1.9%, 1.06%, 1.1.1.1.1.1.1.1.1%, 1.9%, 1.1.1.9%, 1.91%, 1.2%, 1.1.1.1.1.1%, 1.9%, 1.1.9%, 1%, 1.93%, 1.1.1.1.1.1%, 1.1%, 1.9%, 1.8%, 1%, 1.1.1.1.1%, 1%, 1.1.1.1%, 1%, 1.1%, 1%, 1.06, 1.28%, 1.29%, 1.3%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.4%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49% or 1.5% Mg. All expressed in wt.%.
In certain examples, the alloy includes chromium (Cr) in an amount up to about 0.5% (e.g., 0.001% to 0.15%, 0.001% to 0.13%, 0.005% to 0.12%, 0.02% to 0.04%, 0.08% to 0.25%, 0.03% to 0.045%, 0.01% to 0.06%, 0.035% to 0.045%, 0.004% to 0.08%, 0.06% to 0.13%, 0.06% to 0.18%, 0.1 to 0.13%, or 0.11% to 0.12%) by total weight of the alloy. For example, the alloy may comprise 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.011%, 0.012%, 0.013%, 0.014%, 0.015%, 0.02%, 0.025%, 0.03%, 0.035%, 0.04%, 0.045%, 0.05%, 0.055%, 0.06%, 0.065%, 0.07%, 0.075%, 0.08%, 0.085%, 0.09%, 0.095%, 0.1%, 0.105%, 0.11%, 0.115%, 0.12%, 0.125%, 0.13%, 0.135%, 0.14%, 0.145%, 0.15%, 0.155%, 0.16%, 0.165%, 0.17%, 0.175%, 0.18%, 0.185%, 0.19%, 0.195%, 0.2%, 0.1%, 0.14%, 0.145%, 0.15%, 0.35%, 0.31%, 0.35%, 0.30%, 0.35%, 0.30%, 0.35%, 0.30%, 0.35%, 0., 0.36%, 0.365%, 0.37%, 0.375%, 0.38%, 0.385%, 0.39%, 0.395%, 0.4%, 0.405%, 0.41%, 0.415%, 0.42%, 0.425%, 0.43%, 0.435%, 0.44%, 0.445%, 0.45%, 0.455%, 0.46%, 0.465%, 0.47%, 0.475%, 0.48%, 0.485%, 0.49%, 0.495%, or 0.5% Cr. In certain aspects, Cr is not present in the alloy (i.e., 0%). All expressed in wt.%.
In certain examples, the alloy includes nickel (Ni) in an amount up to about 0.01% (e.g., 0.001% to 0.01%) by total weight of the alloy. For example, the alloy may comprise 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.011%, 0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.02%, 0.021%, 0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%, 0.031%, 0.032%, 0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.041%, 0.042%, 0.043%, 0.044%, 0.045%, 0.046%, 0.047%, 0.048%, 0.049% or 0.0405% Ni. In certain aspects, Ni is not present in the alloy (i.e., 0%). All expressed in wt.%.
In certain examples, the alloy includes zinc (Zn) in an amount up to about 0.1% (e.g., 0.001% to 0.09%, 0.004% to 0.1%, or 0.06% to 0.1%) by total weight of the alloy. For example, the alloy may comprise 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.011%, 0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.02%, 0.021%, 0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, or 0.1% Zn. In some cases, Zn is not present in the alloy (i.e., 0%). All expressed in wt.%.
In certain examples, the alloy includes titanium (Ti) in an amount up to about 0.1% (e.g., 0.01% to 0.1%) by total weight of the alloy. For example, the alloy may comprise 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.011%, 0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.02%, 0.021%, 0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%, 0.031%, 0.032%, 0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.05%, 0.052%, 0.053%, 0.054%, 0.056%, 0.057%, 0.059%, 0.050.059%, 0.09%, 0.07%, 0.06%, 0.09%, 0.008%, 0.09%, 0.008%, 0.018%, 0.1%, 0.02. All expressed in wt.%.
In certain examples, the alloy includes vanadium (V) in an amount up to about 0.1% (e.g., 0.01% to 0.1%) by total weight of the alloy. For example, the alloy may comprise 0.001%, 0.002%, 0.003%, 0.004%, 0.005%, 0.006%, 0.007%, 0.008%, 0.009%, 0.01%, 0.011%, 0.012%, 0.013%, 0.014%, 0.015%, 0.016%, 0.017%, 0.018%, 0.019%, 0.02%, 0.021%, 0.022%, 0.023%, 0.024%, 0.025%, 0.026%, 0.027%, 0.028%, 0.029%, 0.03%, 0.031%, 0.032%, 0.033%, 0.034%, 0.035%, 0.036%, 0.037%, 0.038%, 0.039%, 0.04%, 0.05%, 0.052%, 0.053%, 0.054%, 0.056%, 0.057%, 0.058%, 0.059%, 0.09%, 0.07%, 0.06%, 0.09%, 0.9%, 0.09%, 0.9%, 0.0.02%, 0.02. All expressed in wt.%.
Optionally, the alloy compositions described herein may further comprise other trace elements, sometimes referred to as impurities, in an amount of about 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less. These impurities may include, but are not limited to, Ga, Ca, Hf, Sr, Sc, Sn, Zr, or combinations thereof. Thus, Ga, Ca, Hf, Sr, Sc, Sn or Zr may be present in the alloy in the following amounts: 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less. In certain examples, the sum of all impurities does not exceed about 0.15% (e.g., 0.1%). All expressed in wt.%. In some examples, the remaining percentage of the alloy is aluminum.
Manufacturing method
An exemplary thermal history is shown in FIG. 1. An exemplary cold rolled aluminum alloy (e.g., alloy C1, see table 1) is subjected to a solutionizing step to distribute the alloying elements uniformly throughout the aluminum matrix. The solutionizing step may include heating rolled alloy C1 above a solutionizing temperature 101 sufficient to soften the aluminum without melting and maintaining the alloy above the solutionizing temperature 101. The solutionizing step may be performed for a period of time (range a) of about 1 minute to about 5 minutes. Solutionizing allows the alloying elements to diffuse throughout the alloy and be uniformly distributed within the alloy. Once solutionized, the aluminum alloy is rapidly cooled (i.e., quenched) 102 to freeze the alloying elements into place and prevent the alloying elements from agglomerating and precipitating out of the aluminum matrix. In the example shown in fig. 1, the quenching is discontinuous.
In some examples, the discrete quenching step may comprise quenching to a first temperature 103 by a first method and subsequently quenching to a second temperature 104 by a second method. In some examples, a third quench to a third temperature may be included. In some non-limiting examples, the first quench temperature 103 can be about 150 ℃ to about 300 ℃ (e.g., about 250 ℃). In some cases, the first quenching step may be performed with water. In some non-limiting examples, the second quench temperature 104 can be room temperature ("RT") (e.g., about 20 ℃ to about 25 ℃, including 20 ℃, 21 ℃, 22 ℃, 23 ℃, 24 ℃, or 25 ℃). In some examples, the second quenching step may be performed with air.
In some examples, the discrete quenching step may comprise quenching to a first temperature 103 by a first method and subsequently quenching to a second temperature 104 by a second method. In some examples, the first method comprises quenching in a salt bath. In some examples, the second method comprises quenching with air or water. In some examples, the discrete quenching step may further comprise a third quenching to a third temperature.
In some other examples, a heat treatment step (i.e., flash heat) 130 is included. In some cases, the flash-heat (FX) step comprises maintaining the first temperature 103 in the salt bath for a period of time of about 10 seconds to about 60 seconds. After FX step, the alloy may be further quenched to a second temperature. After the flash-heating step and the further quenching step, the coil may be cooled to room temperature and then subjected to further processing steps, e.g., pre-aging or other steps.
In some other examples, the flash heating step is performed independently of the quenching step. The flash heat step comprises heating the aluminum alloy from the second temperature 104 to an FX temperature of about 180 ℃ to about 250 ℃ and maintaining the FX temperature for about 10 seconds to about 60 seconds (not shown). In some cases, the quenching step is continuous. In some other examples, the quenching step may be performed with air. In some other cases, the quenching step may be performed with water. In some non-limiting examples, the quenching step is discontinuous as described herein. After the flash-heat step, the coil may be cooled to room temperature and then subjected to additional processing steps, such as pre-aging or other steps.
In some non-limiting examples, solutionized and quenched alloy C1 may then undergo an aging procedure after the quenching step. In some examples, the aging step is performed about 1 minute to about 20 minutes (range B) after the quenching step. In some non-limiting examples, the aging procedure includes a pre-aging step 110 (laboratory background) or 111 (manufacturing background) and a paint baking step 120. The pre-aging step 110 may be performed for about 1 hour to about 4 hours (range C). In some non-limiting examples, the pre-aging step 110 can provide an aluminum alloy in the T4 temper. The pre-aging step 110 may be a preliminary heat treatment that does not significantly affect the mechanical properties of the aluminum alloy, whereas the aging step 110 may partially age the aluminum alloy such that further downstream heat treatments may complete the artificial aging process. For example, the pre-aging step, the deforming step, and the paint-baking step are artificial aging processes that produce the T8x temper condition in a cold rolled aluminum alloy. In some examples, the T8x state is indicated by the amount of deformation, the heat treatment temperature, and the time period of the heat treatment (e.g., 2% +170 ℃ -20 minutes). Pre-aging in manufacturing context 111 may include heating to a pre-aging temperature and cooling for a period of time that may be greater than 24 hours. In some examples, the alloy is not subjected to a paint bake step, resulting in T4 state condition 115. In some cases, the paint-baking step is performed by the end user. In some other examples, the alloy is not heat treated at all, resulting in an F state condition 116. In some examples, the aging process may increase the strength (i.e., bake hardening) of the aluminum alloy. Generally, the increase in strength due to aging provides an aluminum alloy with poor formability, because the increased strength may be a result of hardening of the aluminum alloy. The entire aging process may be carried out for about 1 week to about 6 months (range D).
In some non-limiting examples, the discontinuous quench technique provides greater bake hardening than an aluminum alloy that is fully quenched to room temperature after solutionizing by a continuous process.
In some further examples, a heat treatment step (i.e., flash heat) may be included. In some cases, once solutionized, the aluminum alloy may be quenched to room temperature. The quenched alloy may then be reheated to a second temperature for a period of time. In some such examples, the second temperature may be between about 180 ℃ to about 250 ℃, e.g., 200 ℃, and the second temperature may be maintained for a time of about 10 seconds to 60 seconds. The alloy may then be cooled to room temperature by a second step quenching step. In some examples, the second quenching step may be performed with air. In some examples, the second quenching step may be performed with water. In some examples, flash heating may be performed less than about 20 minutes after the alloy is quenched to room temperature, for example, after about 10 minutes, 9 minutes, 8 minutes, 7 minutes, 6 minutes, 5 minutes, 4 minutes, 3 minutes, 2 minutes, or 1 minute at about room temperature.
In some non-limiting examples, aging may be performed. In some examples, aluminum alloy sheet, plate or plate may be coated. In some other examples, aluminum alloy sheet, plate, or plate may be heat treated. In some still further examples, the heat treatment may further age the aluminum alloy sheet, plate, or plate.
The following illustrative examples are given to introduce the reader to the general subject matter discussed herein and are not intended to limit the scope of the disclosed concepts. Various additional features and examples are described in the following section with reference to the figures, where like numerals represent like elements, and the directional descriptions are used to describe the illustrative embodiments, but similar to the illustrative embodiments, should not be used to limit the disclosure. The elements contained in the illustrations herein may not be drawn to scale.
Examples of the invention
Example 1
FIG. 2 is a graph of the thermal history of alloy C1 during an exemplary quenching technique and a comparative continuous quenching technique. For comparison, a continuous all water quench (FWQ) and a continuous air-only quench (AQ) are shown. The discontinuous exemplary process was started at various alloy C1 coil temperatures including 500 ℃ and 450 ℃ upon exit from the solid-phase furnace. The water quenching was carried out at various water spray pressures including 6 bar (b) and 2 bar (b). The chart details the rapid cooling of FWQ and the slower cooling of AQ. Alloy C1 was quenched by an exemplary discrete quench, beginning with the alloy exiting the solid-state furnace, cooled to 500 ℃ (designated "5006 b" and "5002 b") by air quenching, showing rapid cooling of the alloy without a second, slower quenching step. Alloy C1 samples quenched by the exemplary discontinuous quench exhibited a discontinuity as the quench was changed from being carried out with water to being carried out with air at about 250 ℃. The alloy temperature upon exiting the solid-phase furnace was 540 ℃, quenched with air to a temperature of about 450 ℃, then quenched with water to a temperature of about 250 ℃, and then quenched with air to about room temperature (referred to as "4506 b" and "4502 b").
Fig. 3 shows the yield strength test results for the alloy C1 sample described above after the optional artificial aging process described above was employed. Shown in the graph is the increase in yield strength of alloy C1 that underwent an exemplary discrete quench that began with a first quench with water as the solutionized coil exited the solid solution furnace and then became a second quench with air as the coil cooled to about 250 ℃. The exemplary alloy subjected to the exemplary quenching and optional deformation and aging produced the exemplary T8x temper.
Fig. 4 presents the difference in yield strength of an exemplary alloy C1 sample in the exemplary T8x temper versus a comparative alloy C1 sample in the T4 temper. The comparative alloy C1 sample underwent natural aging, resulting in the T4 state. The Bake Hardening (BH) response indicated on the y-axis is the result of subtracting the reported yield strength of alloy C1 in the comparative T4 temper from the reported yield strength of alloy C1 in the exemplary T8x temper. As is evident in the graph, the yield strength of alloy C1, which underwent the exemplary discontinuous quench, increased more as compared to the yield strength of comparative alloy C1, which underwent either Full Water Quenching (FWQ) or Air Quenching (AQ) as the sole quenching procedure.
Fig. 5 presents the results of an exemplary alloy C1 subjected to an exemplary discontinuous quench technique, where the quench method was varied at various temperatures. The exemplary alloy C1 did not undergo an optional pre-aging step. The exemplary alloy C1 shown in fig. 5 was subjected to an optional paint bake step. Shown in the graph is the optimum temperature for the discontinuity in the exemplary quenching technique, which is about 250 ℃ (i.e., quenching changes from water to air at about 250 ℃).
Example 2
Fig. 6 presents the yield strength test results of exemplary quench deformation and paint bake techniques employed during processing of exemplary aluminum alloys having various Mn contents. Exemplary aluminum alloys V1 and V2 compositions in this example are described in table 2 (with the balance components consistent with the examples described herein):
TABLE 2 exemplary alloy compositions
| Alloy (I) | Si | Fe | Cu | Mn | Mg |
| V1 | 0.85 | 0.20 | 0.08 | 0.07 | 0.65 |
| V2 | 0.85 | 0.20 | 0.08 | 0.20 | 0.65 |
Fig. 6 shows the increase in yield strength of exemplary alloy V1 and exemplary alloy V2 undergoing exemplary discrete quenching, beginning with an air quench as the solutionized coil exits the solid solution furnace and becomes a water quench to a temperature of about 450 ℃ and then an air quench as the coil cools to about 250 ℃. The alloy subjected to the exemplary quenching, deformation and aging (2% strain then heated to 185 ℃ and held at 185 ℃ for 20 minutes) produced the exemplary T8x temper. In fig. 6, the first histogram bar in each set of bars shows the yield strength of the samples subjected to successive Full Water Quenches (FWQ); the second histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench, starting with the alloy exiting the solid-solution furnace and reaching a temperature of 500 ℃, at a water spray pressure of 6 bar; the third histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench, starting with the alloy exiting the solid-solution furnace and reaching a temperature of 500 ℃, at a water spray pressure of 2 bar; the fourth histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench, starting with the alloy exiting the solid-solution furnace and reaching a temperature of 450 ℃, at a water spray pressure of 6 bar; the fifth histogram bar in each set (the fifth bar of the second set is not included in fig. 6) shows the yield strength of the samples quenched by an exemplary discontinuous quench, starting from the alloy exiting the solid-state furnace and reaching a temperature of 450 ℃, at a water spray pressure of 2 bar; and the sixth histogram bar in each set of bars shows the yield strength of the samples subjected to successive air-only quenching.
The effect of increasing the Mn content in the composition of exemplary alloy V1 is also shown in fig. 6. The exemplary T8x temper was achieved when the exemplary quench started by air quenching the alloy V1 coil to a temperature of 450 c or 500 c, to water and to 250 c, and then to room temperature. Fig. 7 presents the difference in yield strength for the exemplary alloy V1 and V2 samples of the exemplary T8x temper and the comparative T4 temper. The Bake Hardening (BH) response indicated on the y-axis is the result of subtracting the recorded yield strengths of alloys V1 and V2 in the T4 temper from the recorded yield strengths of alloys V1 and V2 in the exemplary T8x temper. Fig. 7 shows that the yield strength of alloys V1 and V2 that underwent the exemplary discrete quench increased more, starting with a water quench when the solutionized coil exited the solid solution furnace and cooled to 450 ℃ or 500 ℃, and becoming an air quench when the coil cooled to about 250 ℃. Also evident is the effect of increasing the Mn content in the exemplary alloy V1 composition. In fig. 7, the first histogram bar in each set of bars shows the yield strength of the samples subjected to successive Full Water Quenches (FWQ); the second histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench starting with the alloy exiting the solid-phase furnace and quenched with air until the temperature reaches 500 ℃, with a water spray (pressure 6 bar) to 250 ℃, and then quenched with air to room temperature; the third histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench starting with the alloy exiting the solid-phase furnace and quenched with air until the temperature reaches 500 ℃, with a water spray (pressure of 2 bar) to 250 ℃, and then quenched with air to room temperature; the fourth histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench starting with the alloy exiting the solid phase furnace and quenched with air until the temperature reaches 450 ℃, with a water spray (pressure 6 bar) to 250 ℃, and then air to room temperature; the fifth histogram bar in each set (the fifth bar of the second set is not included in fig. 7) shows the yield strength of samples quenched by an exemplary discontinuous quench starting from the alloy exiting the solid-solution furnace and quenched with air until the temperature reaches 450 ℃, quenched with a water spray (pressure 2 bar) to 250 ℃, and then quenched with air to room temperature; and the sixth histogram bar in each set of bars shows the yield strength of the samples subjected to successive air-only quenching.
FIG. 8 is a bar graph showing the yield strength of alloy V1 when alloy V1 was in the T4 state (left set of histograms) and alloy V1 was in the exemplary T8x state (right set of histograms). The first histogram bar in each set of bars shows the yield strength of the samples that underwent full water quenching; the second histogram bar in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench; and the third histogram bar in each set shows the yield strength of the samples quenched with successive air-only quenches.
Example 3
Fig. 9 shows the yield strength test results for samples having compositions including alloy a1 (see table 1) produced in the manufacturing context. Alloy a1 was subjected to various quenching techniques during processing. As shown in fig. 9, a full water quench (first set of histogram bars, referred to as "standard water"), an air-only quench (fourth set of histogram bars, referred to as "standard air"), and an exemplary discontinuous quench that begins with exiting the solid-solution furnace and then quenching with water to temperatures of 100 ℃ (second set of histogram bars, referred to as "water, exit at 100 ℃) and 220 ℃ (third set of histogram bars, referred to as" water, exit at 220 ℃) were employed. The yield strength after natural aging (T4 temper) and deformation plus artificial aging (T8x temper, 2% strain then heated to 185 ℃ and held at 185 ℃ for 20 minutes) is shown. Fig. 9 shows the effect of an exemplary quenching technique on an aluminum alloy with higher Cu content processed in the manufacturing context.
FIG. 10 presents the difference in yield strength for the alloy A1 sample under exemplary T8x temper and the comparative T4 temper. The Bake Hardening (BH) response indicated on the y-axis is the result of subtracting the recorded yield strength of alloy a1 in the T4 state from the recorded yield strength of alloy a1 in the T8x state, as presented in fig. 9.
Example 4
Fig. 11 shows the yield strength test results for the alloy G1 sample described above after employing the optional artificial aging process described above to produce the exemplary T8x state (upper line graph) and the natural aging process to produce the T4 state (lower line graph). Fig. 11 shows the increase in yield strength of alloy G1 undergoing an exemplary discontinuous quench, ending the water quench and beginning the air quench when the solutionized coil temperature is between about 100 ℃ and 300 ℃. Alloy G1, subjected to exemplary quenching and optional aging, produced an exemplary T8x temper. Also evident is the increase in yield strength of the naturally aged alloy G1 undergoing the exemplary discrete quench, ending the water quench and beginning the air quench when the solutionized coil temperature is between about 200 ℃ and 300 ℃. It is evident from the graph that quenching needs to be completed at aluminum alloy temperatures between about 100 c and 200 c. Fig. 12 shows the difference in yield strength in an example T8x temper alloy G1 sample compared to a comparative alloy G1 sample that has not undergone an example discrete quench and optional artificial aging (e.g., under T4 temper). The Bake Hardening (BH) response indicated on the y-axis is the result of subtracting the yield strength of the comparative alloy G1 in the T4 recorded from the yield strength of the alloy G1 in the exemplary T8x recorded.
Example 5
Exemplary alloy C1 was subjected to various processes as described herein. In one example, after cold rolling, alloy C1 was Solutionized (SHT), Air Quenched (AQ) and pre-aged (PX) (referred to as "a" in fig. 13 and table 3). In another example, alloy C1 was solutionized, air quenched, flash heated (FX) for various times, further air quenched and pre-aged (referred to as "B" in fig. 13 and table 3). In another example, alloy C1 was solutionized, flash heated (FX) for various times, then air quenched and pre-aged (referred to as "C" in fig. 13 and table 3).
Fig. 13 shows the bake hardening response of an exemplary alloy C1 when subjected to the improved process described herein (see table 1). In a second exemplary process, after quenching, the room temperature alloy is reheated to about 200 ℃ and maintained at 200 ℃ for about 10 seconds. Reheating (i.e., flash heating) improves the bake hardening response of the alloy. The central histogram B of fig. 13 shows an increase in yield strength of about 23 MPa. In another example, during the discrete quench (see fig. 1), when the alloy reaches a discrete temperature (e.g., 200 ℃), the alloy temperature is maintained for a period of time 130 before the secondary quench begins. It is evident in histogram C on the right of fig. 13 that the alloy yield strength increases by about 25 MPa. The strength results are shown in table 3.
TABLE 3 Effect of flash Heat
Rp0.2 yield strength, Rm tensile strength, DC bending angle, and BH bake hardening
As is evident in table 3, the increase in strength of alloy C1 in the T8x (2% +170 ℃ -20 minutes) temper when subjected to the exemplary pre-aging combined with flash heating steps. The T4 temper indicated that alloy C1 did not undergo pre-aging and flash heating. BH indicates the strength increase when the exemplary process provides an alloy at T8 x.
Example 6
In some examples, employing the example methods described herein may reduce the delivery of high strength aluminum alloy products by eliminating any need for long-term heat treatment (i.e., solutionizing)The required processing time. In some examples, an aluminum alloy, for example, sample alloy B1, may be subjected to a comparative process comprising a long solutionizing step followed by a water quench that may comprise passing the aluminum alloy through a cascade of overflow streams, and optionally employing additional heat treatments to artificially age the aluminum alloy and provide an aluminum alloy in the T8 or T8x temper. In some non-limiting examples, sample alloy B1 (having the same composition as the alloy subjected to the comparative process described above) was produced according to the exemplary discontinuous quench method described herein. Exemplary discontinuous quenching provides a process in which the solutionizing step is shortened (e.g., solutionizing proceeds for 25% less time than the solutionizing step of a comparative process), and the discontinuous quenching requires less water (e.g., the cascading overflow can be 105 cubic meters per hour (m)3H), and an exemplary method may use about 27m3H to about 40m3H (e.g., 27 m)3/h、28m3/h、29m3/h、30m3/h、31m3/h、32m3/h、33m3/h、34m3/h、35m3/h、36m3/h、37m3/h、38m3/h、39m3H or 40m3H)). Additionally, pre-aging provides an aluminum alloy in the T4 temper that can be further strengthened by additional heat treatments to provide an aluminum alloy in the T8 or T8x temper (e.g., artificial aging can be performed by the customer during, for example, a paint bake procedure and/or post-forming heat treatment). In some examples, pre-aging performed in this manner is used to partially age the aluminum alloy (e.g., to provide an aluminum alloy in the T4 temper, which may be further artificially aged to provide an aluminum alloy in the T8 or T8x temper, for example). In some aspects, the pre-aging prevents natural aging in the aluminum alloy. In some further examples, the aluminum alloy is subjected to a paint bake procedure after the exemplary discontinuous quench and pre-aging, completing the artificially aged aluminum alloy and providing alloy B1 in the exemplary T8x temper. FIG. 14 is a graph showing the resulting strength after the paint bake procedure for alloys produced at different line speeds. Alloy B1 was processed at a line speed of 20 meters per minute (m/min) with a water quench rate of 105m3H (left histogram of each group), line speed 24.5m/min, water quenchingSpeed of 40m3H (central histogram of each group) and a water quenching rate of 27m at a linear velocity of 24.5m/min3H is used as the reference value. "DL" (center and right histogram in each group) indicates that an exemplary multi-step quenching method is employed. For alloy B1 in the T4 temper, the sample produced by the exemplary method exhibited similar tensile strength (i.e., 20m/min, with a long duration solutionizing step and an overflow water quench) as the sample produced by the comparative conventional method. The samples were further subjected to a paint-bake procedure comprising a heat treatment at a temperature of 185 ℃ for 20 minutes after 2% pre-strain. The tensile strength of all samples increased significantly after paint bake, however the samples produced by the exemplary quenching and pre-aging exhibited higher tensile strength than the samples produced by the comparative conventional method. High strength aluminum alloys can be achieved at a rate 25% faster than conventional methods, thereby reducing time and cost due to shorter heat treatments.
Fig. 15 is a graph showing the effect of various solution heat treatment techniques (referred to as "full SHT" and "short SHT"), various quenching techniques, various pre-strain techniques (e.g., no pre-strain or pre-strain of 2%), and various paint bake techniques (x-axis) on the tensile strength of alloy B1 samples produced according to the exemplary discontinuous quench methods described herein. Each alloy B1 analyzed in this example included the same composition. The left histogram of each set shows that the alloy B1 sample underwent a relatively slow line speed (20m/min), standard solution heat treatment (referred to as "full SHT"), and 105m3Standard water quench of/h (referred to as "full WQ"). The subsequent pre-strain technique and the baking finish technique are shown on the x-axis. The center and right histograms in each set show that the alloy B1 samples underwent a faster line speed (e.g., 24.5m/min), an exemplary 25% shorter solution heat treatment (referred to as "short SHT"), and an exemplary discontinuous quench technique that required less water for the water quenching step of the exemplary discontinuous quench technique (e.g., 40m3H (central histogram) and 27m3H (right histogram)). The subsequent pre-strain technique and the baking finish technique are shown on the x-axis. After paint-baking, the tensile strength of all samples subjected to similar paint-baking (i.e., paint-baking at a temperature of about 165 ℃ to about 185 ℃ for about 10 minutes to about 20 minutes)Is significantly increased. An exemplary processing route that includes a multi-step quenching procedure and a flash-heat step may be used to provide an aluminum alloy in the T4 temper that may be further strengthened when subjected to additional hot working techniques. For example, the aluminum alloys described herein may be produced according to the methods described above and delivered to customers in the T4 temper. The customer may optionally employ additional heat treatments (e.g., baking finish after the painting process or post-forming heat treatment after the forming process) to further artificially age the aluminum alloy and provide aluminum alloys in the T8 or T8x temper.
Example 7
FIG. 16 presents the results of yield strength testing for exemplary quench deformation and various paint bake techniques employed during processing of exemplary aluminum alloys. An exemplary aluminum alloy V1 composition in this example is described in table 2 above.
Fig. 16 shows the increased yield strength of an exemplary alloy V1 that underwent an exemplary discontinuous quench, starting with an air quench as the solutionized coil exits the solid solution furnace and becomes a water quench, and then returning to the air quench for the remainder of the quench. Alloys subjected to exemplary quenching, deformation (e.g., 2% strain applied to yield strength test specimens), and various paint-baking produce an exemplary T8x temper. The baking varnish variations included (i) heating to 165 ℃ and holding at 165 ℃ for 15 minutes (represented by squares), (ii) heating to 175 ℃ and holding at 175 ℃ for 20 minutes (represented by circles), (iii) heating to 180 ℃ and holding at 180 ℃ for 20 minutes (represented by triangles), and (iv) heating to 185 ℃ and holding at 185 ℃ for 20 minutes (represented by diamonds). In fig. 16, the left-hand point in each graph shows the yield strength of the sample subjected to continuous air quenching; the second point from the left in each figure shows the yield strength of the sample quenched by the exemplary discontinuous quench described herein (referred to as "super T8x quench 1"); the third point from the left in each figure shows the yield strength of the sample quenched by the exemplary discontinuous quench described herein (referred to as the "super T8x quench 2"); and the right hand point in each figure shows the yield strength of the samples subjected to successive full water quenches.
FIG. 17 presents the difference in yield strength for the exemplary alloy V1 sample in the exemplary T8x temper and the comparative T4 temper. The Bake Hardening (BH) response indicated on the y-axis is the result of subtracting the yield strength of alloy V1 in the T4 recorded from the yield strength of alloy V1 in the exemplary T8x recorded. As shown in fig. 17, alloy V1 underwent an exemplary discrete quench, deformation (e.g., 2% strain applied to the yield strength test specimen), and various baking finishes to produce an exemplary T8x temper. The baking varnish variations included (i) heating to 165 ℃ and holding at 165 ℃ for 15 minutes (represented by squares), (ii) heating to 175 ℃ and holding at 175 ℃ for 20 minutes (represented by circles), (iii) heating to 180 ℃ and holding at 180 ℃ for 20 minutes (represented by triangles), and (iv) heating to 185 ℃ and holding at 185 ℃ for 20 minutes (represented by diamonds). In fig. 17, the left-hand point in each graph shows the yield strength of the sample subjected to continuous air quenching; the second point from the left in each figure shows the yield strength of the sample quenched by the exemplary discontinuous quench described herein (referred to as "super T8x quench 1"); the third point from the left in each figure shows the yield strength of the sample quenched by the exemplary discontinuous quench described herein (referred to as the "super T8x quench 2"); and the right hand point in each figure shows the yield strength of the samples subjected to successive full water quenches.
As is evident in fig. 16 and 17, the exemplary discontinuous quench technique provides an alloy with increased yield strength regardless of the paint bake procedure applied to the alloy. In addition, a greater bake hardening response was observed after quenching 2 with the above-described ultra T8 x.
FIG. 18 presents a sample after processing three aluminum alloys: sample X, sample Y and sample Z, and the results of yield strength testing using various paint bake techniques.
Fig. 18 shows the increased yield strength of exemplary aluminum alloy samples X, Y and Z undergoing exemplary discrete quenching, beginning with air quenching as the solutionized coil exits the solid solution furnace and becomes water quenched, and then returning to air quenching for the remainder of the discrete quenching. Alloys subjected to exemplary quenching, deformation (e.g., 2% strain applied to yield strength test specimens), and paint baking provide an exemplary T8x temper. The baking varnish involves heating to 185 ℃ and maintaining 185 ℃ for 20 minutes. In fig. 18, the left histogram in each group shows the yield strength of the samples subjected to successive full water quenches; the second histogram from the left in each set shows the yield strength of the samples quenched by an exemplary discontinuous quench in the first test (referred to as "ultra T8x quench 1"); the right histogram in each set shows the yield strength of the samples quenched by the exemplary discontinuous quench in the second test (referred to as "over T8x quench 2").
Fig. 19 presents the difference in yield strength for the exemplary T8x temper and the comparative T4 temper for aluminum alloy samples X, Y and Z. The Bake Hardening (BH) response indicated on the y-axis is the result of subtracting the reported yield strengths of aluminum alloy samples X, Y and Z in the T4 temper from the reported yield strengths of aluminum alloy samples X, Y and Z in the exemplary T8x temper. As shown in fig. 19, aluminum alloy samples X, Y and Z underwent an exemplary discontinuous quench, deformation (e.g., 2% strain applied to the yield strength test sample), and paint bake provided an exemplary T8x temper. The baking varnish involves heating to 185 ℃ and maintaining 185 ℃ for 20 minutes. In fig. 19, the left histogram in each group shows the yield strength of the samples subjected to successive full water quenches; the second histogram from the left in each group shows the yield strength of samples quenched by the exemplary discontinuous quench described herein (referred to as "super T8x quench 1"); the right histogram of alloy a1 shows the yield strength of alloy a1 samples quenched by the exemplary discontinuous quench described herein (referred to as "super T8x quench 2").
As is evident in fig. 18 and 19, the exemplary discontinuous quench technique provides an alloy with improved yield. In addition, a greater bake hardening response was observed after employing the exemplary discontinuous quench technique described above, which exhibited a slight decrease in the bake hardening response except for aluminum alloy sample X.
The foregoing description of the embodiments, including illustrated embodiments, has been presented for the purposes of illustration and description only and is not intended to be exhaustive or to limit the precise forms disclosed. Many modifications, adaptations, and uses thereof will be apparent to those skilled in the art.
Claims (35)
1. A method of producing an aluminum alloy, comprising:
casting an aluminum alloy to form a cast aluminum product, wherein the aluminum alloy includes 0.45-1.5 wt.% Si, 0.1-0.5 wt.% Fe, up to 1.5 wt.% Cu, 0.02-0.5 wt.% Mn, 0.45-1.5 wt.% Mg, up to 0.5 wt.% Cr, up to 0.01 wt.% Ni, up to 0.1 wt.% Zn, up to 0.1 wt.% Ti, up to 0.1 wt.% V, and up to 0.15 wt.% impurities, with the remainder being Al;
homogenizing the cast aluminum product;
hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge;
cold rolling the aluminum alloy body to produce an aluminum alloy sheet having a final gauge;
solutionizing the aluminum alloy plate;
quenching the aluminum alloy plate;
rolling the aluminum alloy plate into a coil; and
the coil is aged out of the way,
wherein the quenching comprises a plurality of steps, wherein the plurality of steps comprises:
a first quench to a first temperature, the first quench performed with air, wherein the first temperature is in a range of 400 ℃ to 550 ℃;
a second quench to a second temperature, the second quench being performed with water, wherein the second temperature is in the range of 200 ℃ to 300 ℃; and
a third quenching to a third temperature, the third quenching performed with air, wherein the third temperature is in a range of 20 ℃ to 25 ℃.
2. The method of claim 1, further comprising: flash-heating the coil, the flash-heating comprising heating the coil to a temperature between 180 ℃ and 250 ℃ for 5 seconds to 60 seconds.
3. The method of claim 1 or 2, wherein the method provides improved speed to an aluminum alloy processing line with at least a 20% reduction in aluminum alloy processing time.
4. The method of claim 1 or 2, further comprising pre-aging the coil.
5. The method of claim 4, wherein the quenching and the pre-aging provide an improved yield strength.
6. The method of claim 1 or 2, further comprising pre-straining the coil.
7. The method of claim 1 or 2, further comprising a paint baking step.
8. A method of producing an aluminum alloy, comprising:
casting an aluminum alloy to form a cast aluminum product, wherein the aluminum alloy includes 0.45-1.5 wt.% Si, 0.1-0.5 wt.% Fe, up to 1.5 wt.% Cu, 0.02-0.5 wt.% Mn, 0.45-1.5 wt.% Mg, up to 0.5 wt.% Cr, up to 0.01 wt.% Ni, up to 0.1 wt.% Zn, up to 0.1 wt.% Ti, up to 0.1 wt.% V, and up to 0.15 wt.% impurities, with the remainder being Al;
homogenizing the cast aluminum product;
hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge;
cold rolling the aluminum alloy body to produce an aluminum alloy sheet having a final gauge;
solutionizing the aluminum alloy sheet;
quenching the aluminum alloy plate;
rolling the aluminum alloy plate into a coil; and
the coil is aged out of the way,
wherein the quenching comprises a plurality of steps, wherein the plurality of steps comprises:
a first quench to a first temperature, the first quench performed with air, wherein the first temperature is in a range of 400 ℃ to 550 ℃;
a second quench to a second temperature, the second quench being performed with water, wherein the second temperature is in the range of 200 ℃ to 300 ℃; and
a third quenching to a third temperature, the third quenching performed with air, wherein the third temperature is in a range of 20 ℃ to 25 ℃.
9. The method of claim 8, further comprising: flash-heating the coil, the flash-heating comprising heating the coil to a temperature between 180 ℃ and 250 ℃ for 5 seconds to 60 seconds.
10. The method of claim 8 or 9, wherein the method provides improved speed to an aluminum alloy processing line with at least a 20% reduction in aluminum alloy processing time.
11. The method of claim 8 or 9, further comprising pre-aging the coil.
12. The method of claim 11, wherein the quenching and the pre-aging provide an improved yield strength.
13. The method of claim 8 or 9, further comprising pre-straining the coil.
14. The method of claim 8 or 9, further comprising a paint baking step.
15. A method of producing an aluminum alloy, comprising:
casting an aluminum alloy to form a cast aluminum product, wherein the aluminum alloy includes 0.45-1.5 wt.% Si, 0.1-0.5 wt.% Fe, up to 1.5 wt.% Cu, 0.02-0.5 wt.% Mn, 0.45-1.5 wt.% Mg, up to 0.5 wt.% Cr, up to 0.01 wt.% Ni, up to 0.1 wt.% Zn, up to 0.1 wt.% Ti, up to 0.1 wt.% V, and up to 0.15 wt.% impurities, with the remainder being Al;
homogenizing the cast aluminum product;
hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge;
cold rolling the aluminum alloy body to produce an aluminum alloy sheet having a final gauge;
solutionizing the aluminum alloy sheet;
quenching the aluminum alloy sheet;
rolling the aluminum alloy sheet into a coil; and
the coil is aged out of the way,
wherein the quenching comprises a plurality of steps, wherein the plurality of steps comprises:
a first quench to a first temperature, the first quench performed with air, wherein the first temperature is in a range of 400 ℃ to 550 ℃;
a second quench to a second temperature, the second quench being performed with water, wherein the second temperature is in the range of 200 ℃ to 300 ℃; and
a third quenching to a third temperature, the third quenching performed with air, wherein the third temperature is in a range of 20 ℃ to 25 ℃.
16. The method of claim 15, further comprising: flash-heating the coil, the flash-heating comprising heating the coil to a temperature between 180 ℃ and 250 ℃ for 5 seconds to 60 seconds.
17. The method of claim 15 or 16, wherein the method provides improved speed to an aluminum alloy processing line with at least a 20% reduction in aluminum alloy processing time.
18. The method of claim 15 or 16, further comprising pre-aging the coil.
19. The method of claim 18, wherein the quenching and the pre-aging provide an improved yield strength.
20. The method of claim 15 or 16, further comprising pre-straining the coil.
21. The method of claim 15 or 16, further comprising a paint-baking step.
22. An aluminum alloy product, wherein the aluminum alloy product is produced by the method of any of claims 1-21.
23. A method of producing an aluminum alloy, comprising:
casting an aluminum alloy to form a cast aluminum product, wherein the aluminum alloy includes 0.45-1.5 wt.% Si, 0.1-0.5 wt.% Fe, up to 1.5 wt.% Cu, 0.02-0.5 wt.% Mn, 0.45-1.5 wt.% Mg, up to 0.5 wt.% Cr, up to 0.01 wt.% Ni, up to 0.1 wt.% Zn, up to 0.1 wt.% Ti, up to 0.1 wt.% V, and up to 0.15 wt.% impurities, with the remainder being Al;
homogenizing the cast aluminum product;
hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge;
cold rolling the aluminum alloy body to produce an aluminum alloy sheet having a final gauge;
rolling the aluminum alloy plate into a coil;
solutionizing the coil;
quenching the coil to room temperature;
flashing the coil hot; and
the coil is pre-aged by a pre-aging process,
wherein the quenching comprises a plurality of steps, wherein the plurality of steps comprises:
a first quench to a first temperature, the first quench performed with air, wherein the first temperature is in a range of 400 ℃ to 550 ℃;
a second quench to a second temperature, the second quench being performed with water, wherein the second temperature is in the range of 200 ℃ to 300 ℃; and
a third quenching to a third temperature, the third quenching performed with air, wherein the third temperature is in a range of 20 ℃ to 25 ℃.
24. The method of claim 23, the flash heating step comprising heating the coil to a temperature between 180 ℃ and 250 ℃ for 5 seconds to 60 seconds.
25. The method of any one of claims 23 to 24, further comprising a paint-baking step.
26. The method of claim 25, wherein the flash heat and the baking finish provide improved yield strength.
27. A method of producing an aluminum alloy, comprising:
casting an aluminum alloy to form a cast aluminum product, wherein the aluminum alloy includes 0.45-1.5 wt.% Si, 0.1-0.5 wt.% Fe, up to 1.5 wt.% Cu, 0.02-0.5 wt.% Mn, 0.45-1.5 wt.% Mg, up to 0.5 wt.% Cr, up to 0.01 wt.% Ni, up to 0.1 wt.% Zn, up to 0.1 wt.% Ti, up to 0.1 wt.% V, and up to 0.15 wt.% impurities, with the remainder being Al;
homogenizing the cast aluminum product;
hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge;
cold rolling the aluminum alloy body to produce an aluminum alloy sheet having a final gauge;
rolling the aluminum alloy plate into a coil;
solutionizing the coil;
quenching the coil to room temperature;
flashing the coil hot; and
the coil is pre-aged by a pre-aging process,
wherein the quenching comprises a plurality of steps, wherein the plurality of steps comprises:
a first quench to a first temperature, the first quench performed with air, wherein the first temperature is in a range of 400 ℃ to 550 ℃;
a second quench to a second temperature, the second quench being performed with water, wherein the second temperature is in the range of 200 ℃ to 300 ℃; and
a third quenching to a third temperature, the third quenching performed with air, wherein the third temperature is in a range of 20 ℃ to 25 ℃.
28. The method of claim 27, the flash heating step comprising heating the coil to a temperature between 180 ℃ and 250 ℃ for 5 seconds to 60 seconds.
29. The method of any one of claims 27-28, further comprising a paint-baking step.
30. The method of claim 29, wherein the flash heat and the baking finish provide improved yield strength.
31. A method of producing an aluminum alloy, comprising:
casting an aluminum alloy to form a cast aluminum product, wherein the aluminum alloy includes 0.45-1.5 wt.% Si, 0.1-0.5 wt.% Fe, up to 1.5 wt.% Cu, 0.02-0.5 wt.% Mn, 0.45-1.5 wt.% Mg, up to 0.5 wt.% Cr, up to 0.01 wt.% Ni, up to 0.1 wt.% Zn, up to 0.1 wt.% Ti, up to 0.1 wt.% V, and up to 0.15 wt.% impurities, with the remainder being Al;
homogenizing the cast aluminum product;
hot rolling the cast aluminum product to produce an aluminum alloy body of a first gauge;
cold rolling the aluminum alloy body to produce an aluminum alloy sheet having a final gauge;
rolling the aluminum alloy sheet into a coil;
solutionizing the coil;
quenching the coil to room temperature;
flashing the coil hot; and
the coil is pre-aged by a pre-aging process,
wherein the quenching comprises a plurality of steps, wherein the plurality of steps comprises:
a first quench to a first temperature, the first quench performed with air, wherein the first temperature is in a range of 400 ℃ to 550 ℃;
a second quench to a second temperature, the second quench being performed with water, wherein the second temperature is in the range of 200 ℃ to 300 ℃; and
a third quenching to a third temperature, the third quenching performed with air, wherein the third temperature is in a range of 20 ℃ to 25 ℃.
32. The method of claim 31, the flash heating step comprising heating the coil to a temperature between 180 ℃ and 250 ℃ for 5 seconds to 60 seconds.
33. The method of any one of claims 31-32, further comprising a paint-baking step.
34. The method of claim 33, wherein the flash heat and the baking finish provide improved yield strength.
35. An aluminum alloy product, wherein the aluminum alloy product is produced by the method of any of claims 23-34.
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| PCT/US2017/065766 WO2018111845A1 (en) | 2016-12-16 | 2017-12-12 | Aluminum alloys and methods of making the same |
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| JP6441458B2 (en) * | 2015-03-27 | 2018-12-19 | Ykk株式会社 | Slide fastener element |
| JP7025428B2 (en) | 2016-12-16 | 2022-02-24 | ノベリス・インコーポレイテッド | High-strength and high-formability aluminum alloy resistant to natural aging hardening and its manufacturing method |
| KR102161303B1 (en) * | 2018-09-05 | 2020-10-05 | 한국생산기술연구원 | Heat treatment method of Al alloy |
| CN109722572B (en) * | 2018-12-30 | 2020-06-23 | 精美铝业有限公司 | High-performance aluminum alloy for power transmission and transformation equipment and preparation method thereof |
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| KR102253860B1 (en) | 2021-05-24 |
| US20180171453A1 (en) | 2018-06-21 |
| AU2017375790A1 (en) | 2019-06-20 |
| JP6921957B2 (en) | 2021-08-18 |
| KR20190097158A (en) | 2019-08-20 |
| RU2019119558A (en) | 2021-01-18 |
| ES2857683T3 (en) | 2021-09-29 |
| JP2020509170A (en) | 2020-03-26 |
| WO2018111845A1 (en) | 2018-06-21 |
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